Core board product

ABSTRACT

A core board forming apparatus includes a feeding apparatus for sensing and dispensing tubular cores at predetermined dispensing positions. A compression apparatus receives and detects the tubular cores and flattens and secure at least two flattened tubular cores together. A controller unit controls the operation of the feeding apparatus and the compression apparatus. The presence of first tubular core is detected after the step of dispensing. In response to detecting the first tubular core is substantially flattened. A core board product includes at least two substantially flattened paper cores fastened together by integral fastening members having two fastening portions extending directly through the flattened cores.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a divisional of U.S. application Ser.No. 09/880,079 filed Jun. 14, 2001, which is hereby expresslyincorporated by reference.

FIELD OF THE INVENTION

[0002] The present invention generally relates to a board made fromcores, and more particularly to cores used to accommodate a roll ofpaper in manufacturing paper products.

BACKGROUND OF THE INVENTION

[0003] In producing commercial paper products, large paper rolls areshipped in locomotive rails cars to paper processing plants. In general,the center of the paper rolls contain a 10-foot long “elongated tubularcore” made of liner paper much like a tube found in a toilet tissue rollor a tube in wrapping paper. In the large paper rolls, the typicaltubular core is five inches in diameter having about a one-half inchwall thickness. The paper processing plants use the paper rolls as inputmaterial for processing machines that produce a variety of paperproducts for the residential and commercial markets. In processing, thepaper is unwound from the elongated tubular core of the respective paperroll and the core is typically discarded in a landfill after use.

[0004] In the past, a core board machine included a pneumatic press inwhich tubular cores where flattened between two compression plates. Coreboard was produced by manually placing a core between a stationary plateand a movable plate, which extended towards the stationary plate toflatten the core. The movable plate retracted and one or two cores weremanually placed between the plates and flattened against the first core.While the moveable plate was extended, an operator manually positioned ascrew gun to fasten several screws into the compressed cores to holdthem together. The machine was labor intensive, had limited ability toproduce a large quantity of core board product, and was expensive tomanufacture.

[0005] Core board has been used as a packing material to protect largepaper rolls from damage during transport in rail cars. However, there isa risk that the pointed end of the screws may protrude through thecompressed cores and tear the paper rolls during shipment in the railcars. Further, the screws can have a reduced fastening performance byloosening overtime. Accordingly, there was a need to prevent separationof the compressed cores so that the performance was consistent for thepurpose of a packing material. Since the search is always on forimproved products and lower costs, there is a particular need for anapparatus and a method of producing an improved core board product.

BRIEF SUMMARY OF THE INVENTION

[0006] Briefly, the present invention improves the art by providing anadvanced core board forming apparatus, a method of making core boardproduct and a core board product.

[0007] According to one aspect of the invention, a core board formingapparatus includes a feeding apparatus having a discharge portion fordischarging a tubular core. A compression apparatus has a compressionsurface and a flattening surface movable together to flatten the tubularcore. A conveying portion supports the tubular core at an interimlocation between the compression surface and the flattening surface inan uncompressed condition and releases the tubular core to theflattening surface when the compression surface and flattening surfacemove together to a closed position. A controller unit is configured tocontrol the feeding apparatus and the compression apparatus. In thisway, tubular cores are positioned by the conveying portion tosubstantially align and form a consistent core board product.

[0008] In a second aspect of the invention, a dispensing apparatusincludes a device for detecting tubular cores at a predetermineddispensing position for sequentially dispensing each of the cores. Acompression apparatus has a compression member for substantiallyflattening each of the dispensed tubular cores and a plurality ofpivotable members configured to retain each of the dispensed cores belowthe compression member for conveyance to a flattening plate upondownward contact with the compression member. A processor unit isconfigured to execute computer readable code for controlling thedispensing apparatus and the compression apparatus.

[0009] In a third aspect of the invention, a method of making core boardproduct is under the control of a processing unit. A first tubular coreis dispensed to a conveying portion to support the first tubular core atan interim location. The first tubular core is conveyed to a flatteningposition under pressure of a compression member. The first tubular coreis substantially compressed between the compression member and aflattening surface. The steps of dispensing, conveying, compressing isrepeated for at least a second tubular core. The second tubular issubstantially compressing core against the first tubular core. Then thesubstantially compressed first tubular core and second tubular core arefastened together in an abutting relationship with a plurality offastening members so as to form the core board product.

[0010] A first tubular core is dispensed to a conveying portion above acompression surface. The first tubular core is conveyed under downwardpressure to the compression surface after detecting the presence of thefirst tubular core on the conveying portion. The first tubular core issubstantially compressed on the compression surface. The steps ofdispensing, conveying, compressing is preformed for at least a secondtubular core in which during the step of compressing the compressedfirst tubular core and second tubular core are fastened with a pluralityof fastening members so as to form the core board product.

[0011] In a fourth aspect of the invention, a core board productincludes at least two substantially flattened tubular paper coresfastened together by a plurality of fastening members, the fasteningmembers each has a first fastening portion contacting against only oneof flattened cores and two second fastening portions extending throughthe flattened cores substantially perpendicular to the first fasteningportion. In this way, the core board product prevents tearing abuttingpaper rolls during transportation.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The foregoing summary of the invention as well as the followingdetailed description of the invention considered in conjunction with theaccompanying drawings provides a better understanding of the invention,in which like reference numbers refer to like elements, and wherein:

[0013]FIG. 1 is a schematic front elevational view of an apparatus forforming core board product according to the teachings of the presentinvention;

[0014]FIG. 2 is a schematic front elevational view of the apparatus ofFIG. 1 with a front portion removed to reveal components inside of theapparatus;

[0015]FIG. 3 is a schematic side elevational view of the apparatus ofFIG. 1 according to the teachings of the present invention;

[0016]FIG. 4 is an enlarged fragmentary side view of a dischargingportion of the apparatus shown in FIG. 1;

[0017]FIG. 5 is a side sectional view of the apparatus of FIG. 1;

[0018]FIG. 6 is a schematic diagram of a controller unit of theapparatus of FIG. 1;

[0019] FIGS. 7-10 are side sectional views of the apparatus of FIG. 1illustrating a functional sequence according to the teachings of thepresent invention;

[0020]FIG. 11 is a schematic perspective view of an embodiment of a coreboard product according to the teachings of the present invention;

[0021]FIGS. 12A and 12B are schematic sectional views of alternativefastening arrangements of the core board product shown in FIG. 11 takenalong line 1212.

[0022]FIG. 13 is a fragmentary schematic top plan view of a bottomportion of the apparatus of FIG. 1 illustrating grooves and openings forcontrol devices.

[0023]FIG. 14 is a schematic side elevational view of an embodiment of acore cutting apparatus; and

[0024]FIG. 15 is a fragmentary perspective view of a cutting device ofthe apparatus of FIG. 14.

DETAILED DESCRIPTION OF THE INVENTION

[0025] FIGS. 1-12A, 12B, and 13 illustrate an embodiment of a core boardforming apparatus 1 and a method of producing a core board product 7according to the teachings of the present invention. Apparatus 1comprises a dispensing section 3 for holding and discharging a pluralityof tubular cores 13. A core compression section 5 receives the tubularcores so as to flatten and secure the cores to form the core boardproduct 7 shown in FIG. 11. A microprocessor controller unit 9, shown inFIG. 6, controls the operation of dispensing section 3 and corecompression section 5. The details of apparatus 1 are described indetail below.

[0026] As illustrated in FIGS. 3 and 5, dispensing section 3 includes aholding portion 11 for temporarily storing cores 13. A discharge chute15 is mounted in front of holding portion 11 so that the cores aresequentially conveyed into compression section 5 under control ofcontroller unit 9. In a preferred embodiment, holding portion 11 ofdispensing section 3 is constructed from parallel sidewall plates 17mounted on opposing sides of a downwardly inclined floor plate 19.Vertical supports 18 are mounted to sidewall plates 17 to supportdispensing section 5 above a floor surface 10. Referring to FIG. 5,inclined floor plate 19 is angled approximately 15 degrees from thehorizontal so that cores 13 can roll forward by gravity from holdingportion 11 into the discharge chute 15. The angle of the inclined floorplate is preferably set in a range from 15 degrees to 25 degrees butother inclination angles are possible. As illustrated in FIG. 5, a rearwall plate 21 is fastened to the rear end of sidewall plates 17 andinclined floor plate 19. A front wall plate 23 spans between the frontportions of sidewall plates 17 such that a rearward opening 25 ofdischarge chute 15 is formed between a bottom edge of front wall plate23 and inclined floor plate 19. It should be recognized that there are anumber of approaches and other constructions of the holding portion thatenable storage and movement of cores to discharge chute 15.

[0027] With reference to FIGS. 3-5, in a preferred embodiment, dischargechute 15 has a substantially enclosed shape having rearward opening 25and a forward discharge opening 27. An elongated portion of eachsidewall plate 17 is vertically mounted to the opposite of sides ofinclined floor plate 19 to form discharge chute 15. As shown in FIG. 5,a top plate 29 is affixed to a top edge of the elongated portion of eachsidewall plate 17 to enclose discharge chute 15. The rear end of topplate 29 is affixed to front wall 23 at the bottom edge of front wallplate 23. In one embodiment, as seen in FIGS. 3 and 4, aligned curvedslots 31 are cut into the opposing sidewall plates 17 of the elongatedportion. Top plate 29 includes corresponding horizontally aligned slotopenings 33 extending between curved slots 31.

[0028] In a preferred embodiment, as best seen in FIG. 4, curved slots31 enable a first movable rod 35 and a second movable rod 37 to rotateupwardly so that the core can roll past each rod as requested bycontroller unit 9. Likewise, movable rods 35, 37 rotate downwardly toprevent the cores from rolling into compression section 5. Each end ofmovable rods 35, 37 extends through a hole in a lower end of a pivotmember 39. Likewise, the lower end of a pneumatic actuator 41 ispivotally mounted to the lower end of pivot member 39 via a pivot pin43. Pivot member 39 is constructed from a flat bar having holes thatretain the pivot pin and the ends of movable rods 35, 37. The upper endof pivot member 39 is pivotally mounted to a bracket 45 that is affixedto top plate 29 of discharge chute 15. An upper end of each pneumaticactuator 41 is pivotally fastened to a support bracket 47 is thataffixed to cantilevered support plate 49. Each cantilevered supportplate 49 is substantially aligned with sidewall plates 19 and is affixedto front wall 23 to provide a structure for the supporting actuators 41with support bracket 47.

[0029] With reference to FIG. 4, in a preferred embodiment, coreposition sensors 51, 52 are mounted underneath top plate 29 of dischargechute 15 so that a core abutted against each movable rod 35, 37 can bedetected. Each position sensor 51, 52 is disposed such that a beam oflight is directed just upstream of movable rods 35, 37 to detect thepresence of a core. In essence, position sensors 51, 52 look upstream ofthe rods to see when a core is disposed against rods 35, 37 so that asingle core can be sequentially discharged into compression section 5;however, sensors 51, 52 also sense the absence of a core against therods.

[0030] In an embodiment of the invention, core position sensors 51, 52are a photoelectric sensor that detects an object; however, other typeof sensors may be used, including contact sensors or capacitive sensors.Core position sensors 51, 52 are operatively coupled to microprocessorcontroller unit 9 by interface control hardware, such as wires orwireless connections. This enables controller unit 9 to receive andprocess a detection signal generated by position sensors 51, 52.Referring to FIGS. 3, 4 and 5, in one arrangement, rod position sensors54, 56 may be mounted to top plate 29 to detect when rods 35, 37 are inthe up position. Sensors 54, 56 are preferably proximity sensors thatdetect a magnetic field, but other types sensing devices that detect thepresence of the rods in the up position are contemplated, such asphotoelectric sensors, capacitive sensors, or limit switches. In anembodiment, the detection of the up position of rods 35, 37 can beaccomplished with encoders configured to sense the rotary motion ofpivot member 39. While discharge chute 15 is shown and described, otherarrangements that sequentially dispense cores are possible, such as arotating paddle wheel type.

[0031] Referring to FIGS. 1 and 2, in an embodiment, compression section5 preferably includes a rectangular frame formed by two spaced verticalchannel members 53 and a horizontal channel member 55 affixed to the topend of each vertical channel member 53. As seen in FIGS. 2 and 5, a backplate 57 is mounted between vertical channel members 53. Back plate 57includes an opening adapted to mate with the corresponding dischargeopening 27 of discharge chute 15. The lower end of back plate 57includes a notch opening 59 enabling an unload ram 61 to discharge thecore board product from compression section 5.

[0032] Referring to FIGS. 1, 2, and 5, in a preferred embodiment,compression section 5 includes a press assembly 71 that compresses orflattens a dispensed core against a bottom plate 73. Bottom plate 73 ismounted between vertical channel members 53. Referring to FIGS. 5 and13, bottom plate 73 includes two openings 128 for two optical sensors 75to detect the presence or absence of a dispensed core on the plate, inwhich a beam of light is directed vertically into the openings from thesensors. Sensors 75 are operatively coupled to controller unit 9. Theuse of the detection signal from optical sensors 75 will be describedwith the operation sequence of core board forming apparatus 1. It isrecognized that other types of sensing devices, such as contact orcapacitive sensors may be used, instead of optical sensors 75 to detecta core on the bottom plate.

[0033] As best seen in FIG. 2, in a preferred embodiment, press assembly71 is constructed from a top support member 69, vertical plates 79, anda compression plate 81. Vertical plates 79 serve to physically connecttop support member 69 and compression plate 81 into a single structure.Accordingly, vertical plates 79 are mounted on opposing sides of the topsupport member and the compression plate. A vertical stiffener plate 83is mounted between the midpoint the opposing sides of top support member69 and compression plate 81 to provide enhanced structural support.

[0034] Bearings 82 are mounted to the side of vertical plates 79 so thatpress assembly 71 travels freely against vertical bearing plates 84inside of vertical channel members 53. Bearing 82 are preferably camfollower types, but may also be roller bearing types. Vertical bearingplates 84 are spaced inward from channel members 53. Referring to FIGS.1, 2 and 5, hydraulic actuators 63 vertically move press assembly 71 incompression section 5. The upper ends of actuators 63 are pivotallymounted to the bottom surface of horizontal channel member 55 byattachment tangs 65 and pivot pins 67. Likewise, the lower ends ofhydraulic actuators 55 are pivotally mounted to top support member 69 ofpress assembly 71 by attachment tangs 65 and pivot pins 67. In analternative embodiment, the press assembly can be motor driven andconfigured with gears to move.

[0035] As best seen in FIGS. 1, 2, and 5, a press position sensor 85 ismounted on the inner surface of vertical channel member 53 to detectwhen press assembly 71 is in a full up position. Press position sensor85 generates a detection signal when a magnetic field is created betweena metal bar 87 that is mounted to the upper surface of top supportmember 69; however, other types of sensors may be used for detection,such as limit switches. Similarly as other sensors of apparatus 1, pressposition sensor 85 is operatively coupled to microprocessor controllerunit 9.

[0036] As best shown in FIG. 2, in a preferred embodiment, pressassembly 71 also securely fastens at least two flattened cores togetherby fastening devices, such as pneumatic staple guns 77. Staple guns 77are commercially available and include a staple feeder cartridge 89.Referring to FIGS. 1, 2, and 4, compression plate 81 includes theplurality of staples guns 77 for fastening the flattened cores togetheragainst bottom plate 73. Staple guns 77 are mounted to the upper surfaceof the compression plate 81 via brackets 91. Brackets 91 are mountedsuch that staple guns 77 are secured during vertical movement of pressassembly 71, but can slide out of bracket 91 for maintenance. Notchopenings are included in compression plate 81 so that staple guns 77 caninject staple fasteners into the flattened cores.

[0037] As best seen in FIG. 1, in a preferred embodiment, compressionsection 5 includes a discharge gate 93 mounted inside of a maintenancegate 95. More fully shown in FIG. 10, discharge gate 93 opens verticallyto a predetermined height so that core board product 7 can be dischargedfrom bottom plate 73 by unload ram 61 during the manufacturingoperation. Maintenance gate 95 provides an arrangement for gainingaccess to press assembly 71 and staple guns 77 for maintenance or otherpurposes. Regarding discharge gate 93, a pneumatic actuator 97 movesgate 93 up vertically.

[0038] As seen in FIG. 1, maintenance gate 95 comprises interconnectedhorizontal and vertical angle members 101 forming a rectangular framethat resides inside of the vertical channel members 53. Maintenance gate95 pivots about hinges 99 and discharge gate 93 rotates with gate 95.Referring to FIG. 3, maintenance gate 95 is capable of being pivotedopen by a pneumatic actuator 98 mounted to vertical channel member 53.In use, a rod of actuator 98 pushes down on a wire 100 fed throughpulleys 92 and lifts gate 95 to pivot about hinges 99. As seen in FIG.1, a handle 104 is provided to enable lifting of gate 95. In addition, agate proximity sensor 102 is mounted in the front of vertical channelmember 53 to detect when gate 95 is closed. Again, other types ofsensing devices can be used to detect when gate is closed, such ascontact switches.

[0039] As shown in FIG. 1, discharge gate 93 is preferably slotted toenable vertical movement of staple guns 77 with press assembly 71. Adischarge gate proximity sensor 103 is mounted to the lower front ofvertical channel member 53 to detect when discharge gate 93 is closed. Asecond discharge gate proximity sensor 106 detects when gate 93 is inthe opened position. Sensor 106 is mounted near press position sensor 85on vertical channel member 53. Sensor 103 generates a detection signalwhen a magnetic field is created between a metal bar 105 that is mountedthe lower front of discharge gate 93. Likewise sensor 106 detects amagnetic field created by the upper part of discharge gate 93.Controller unit 9 receives the detection signal preferably by controlwires or, if desired, the detection signal may be transmitted bywireless communication connections. It should be recognized thatalternative types of sensing devices that serve the same purposes assensors 103 and 106 may be used.

[0040] Referring to FIGS. 1, 3 and 5, in a preferred embodiment,compression section 5 further preferably includes a conveying portionformed by rotatable arms or fingers 107. A front set of rotatable arms107 is pivotally mounted to discharge gate 93 and a rear set of arms 107is mounted to back plate 57. As shown in FIG. 5, the front set of arms107 and the rear set of arms 107 form a valley type structure such thatboth sets of arms are sloped towards each other. This enables adispensed core to roll on the arms and to be centered above bottom plate73 of compression section 5.

[0041] As illustrated in FIG. 5, each of rotatable arms 107 has aninclined elongated member 109 including a concave portion at the tip orreceiving end to retain a core lengthwise between the front set and rearset of arm 107. The members 109 contact the outer surface of the tubularcore at discrete locations for conveyance to bottom plate 73. Theopposite end of rotatable arms 107 is counterweighted to enable each armto pivot upwardly to a holding or position as shown. In sum, theconveying portion supports a dispensed tubular core at an interimlocation between compression plate 81 and bottom plate 73 in an openuncompressed condition so that the core can be place at a predeterminedposition on bottom plate 73. The conveying portion also enables a coreto be aligned on top a first compressed core for subsequent compressionare fastening operations.

[0042] An optical sensor 111 is affixed underneath discharge chute 15such that a substantially horizontal beam of light senses the presenceor the absence of a dispensed core retained between the front and rearset of rotatable arms 107. While an optical sensor is shown, acapacitive sensor may be also be used. Other constructions of theconveying portion are possible.

[0043] Referring to FIG. 5, core board forming apparatus 1 furtherincludes an unload ram 61 for removing finished core board product 7from compression section 5. In a preferred embodiment, unload ram 61includes a pneumatic cylinder with a rod having a pushing bar 64configured to push the core board product. Unload ram 61 includes aproximity sensor that detects when it is retracted. The unload ram ishorizontally mounted on beam supports 62 that are fastened to supportmembers 18 and vertical channel members 53.

[0044] Advantageously, microprocessor controller unit 9 may comprise acomputing device for controlling operation core board forming apparatus1. In one embodiment of the invention, controller unit 9 comprises acentral programmable logic control unit (PLC) or a series of independentcentral programmable logic control units configured for providingsemi-automatic or automatic processing operation. Likewise, controllerunit 9 may be a general purpose computer configured to operate with suchprogrammable controllers. Nevertheless, the operational logic sequencesfor controlling core board apparatus 1 can be readily programmed bythose having ordinary skill in the art.

[0045] As shown schematically in FIG. 6, in a preferred embodiment ofthe invention, controller unit 9 comprises a PLC-5 series programmablecontroller including 1771 series digital and analog input/output modulescommercially available through the Allen-Bradley Company of Milwaukee,Wis.; however, other suitable equipment or devices may be used for thecontroller unit. Hardware components of microprocessor controller unit 9may include a processing unit 113, a system memory 115, and a systembackplane 117 that forms a data pathway for input/output modules 123.Input/output modules 123 interface with various control devices, such asthe sensing devices, comprising apparatus 1. Processing unit 113 may beany suitable microprocessor used in industrial control systems. Thesystem backplane 117 may be any of several types of conventionalbackplane structures. System memory 115 includes computer readable codein the form of read only memory (ROM) and random access memory (RAM).System memory 115 stores programmable instructions of the operationallogic sequences 119 that are executed by processing unit 113.

[0046] If desired, controller unit 9 can further include a computerreadable storage device 121 that may comprise an Eraseable ProgrammableRead Only Memory (EPROM) to store data. Storage device 121 andassociated computer-readable media provide nonvolatile storage ofcomputer readable code and logic sequences. Controller unit 9 mayoperate in a networked environment (not shown) using a networkconnection in input/output modules 123. The networked environment mayinclude a local area network (LAN) any number of networking signalingused in industrial control systems, such as Ethernet, Controlnet,Devicenet, or Datahighway plus.

[0047] It should be recognized by one of ordinary skill in the art thata hydraulic system is used for moving the hydraulic actuators incompression section 5. Such a hydraulic system includes a tank, a pump,pipes, hoses and control values. It should be apparent that pneumatic orair operated components described are interconnected to a pneumaticsystem in which the intended function of the component is controlled bymicroprocessor controller unit 9 via an air control valve (not shown).The control valve includes a solenoid that opens and closes according toan electrical signal transmitted by the controller unit. Such apneumatic system includes an air compressor, filters, hoses, pipes, andregulators. In addition, the pump motor and air compressor motor may beinterlocked with microprocessor controller unit 9 via contact relays(not shown) to provide electric power for operation. Other constructionsof the hydraulic and pneumatic system are possible.

[0048] FIGS. 7-10 illustrate a functional overview of a method of makingcore board product in accordance with the present invention, as carriedout by core board forming apparatus 1. An operational cycle is hereindefined as compression and securing of at least two cores together;however more cores may be used. For ease of explanation, use of the term“cores” denotes a generic tubular paper core without reference to thelength. One arrangement, the elongated tubular cores can be cut intosmaller core section. This enables the core board product have differentlengths as a packing material or other purposes.

[0049] An embodiment of the dispensing or discharging sequence ofdispensing section 3 is described below. Referring to FIG. 7, cores 13have been placed in holding portion 11 of dispensing section 3. Atdischarge chute 15, first and second moveable rods 35, 37, respectively,are in a closed position to block the cores from freely rolling into thecompression section. In use, the cores at the bottom of dispensingsection 5 roll forward on incline floor plate 19 towards discharge chute15 and a core abuts against the first moveable rod 35. At this position,upstream core position sensor 51 detects the presence of a core in afirst discharge position.

[0050] Still referring to FIG. 7, upon detection of the core in thefirst position, a detection signal is processed by microprocessor unit 9to actuate a control valve (not shown) that operates pneumatic actuators41 connected to first moveable rod 35. The lowered end of actuator 41lifts upward to impart an upward rotation of pivot member 39 and firstmovable rod 35. The first movable rod follows the curvature of thecurved slots 31 in discharge chute 15. Eventually, first movable rod 35rotates upward just enough to enable the core to roll under the rod. Inthis point, the presence of the core is detected by downstream coreposition sensor 52. In one arrangement, an alert condition indicatesthat the core might be misaligned in discharge chute 15. The alertcondition is programmed to activate when rod 35 is detected in the upposition by rod position sensor 54 and the absence of a core is detectedby core position sensor 52.

[0051] In a preferred embodiment, a second discharge position is definedwhen a core in disposed between the first and second moveable rods. Inthe second discharge position and after a short time delay, such as 1.5seconds, the first movable rod is rotated back down into the closedposition. Second movable rod 37 is rotated upward by its pneumaticactuators 41 to allow the core to roll under the rod when it receives acore request signal from microprocessor controller unit 9.Advantageously, sensors 51, 52 detect the tubular core at predeterminedfirst and second dispensing positions to ensure sequentially dischargingthe cores.

[0052] An embodiment of the operation of the compression section isdescribed below. In a preferred embodiment, a first core request signalis generated at the start of the operational cycle in which themicroprocessor unit scans the sensors 75, 85, 102, 103, 111 so thatcompression section 5 is ready to accept a core. For example, opticalsensors 75 at bottom plate 73 detects that there is the absence of acore in compression section 5. Press assembly 71 is detected in the fullup position. Maintenance gate 93 and discharge gate 95 are detected asclosed. Optical sensors 111 detect absence of a core on arms 107.

[0053] As shown in FIG. 8, the first core request signal has beengenerated and a dispensed core 125 has been conveyed from dispensingsection 3 on to the conveying portion formed by rotatable arms 107. Inthis point in the operational sequence, optical sensor 111 detects thepresence of the dispensed core on arms 107. In one arrangement, an alertcondition is programmed to activate when rod 37 is detected in the upposition by rod position sensor 56 and the absence of a core is detectedby optical sensor 111.

[0054] As shown in FIG. 9, upon detection of the dispensed core 125, adetection signal is processed by microprocessor unit 9 to actuate acontrol valve (not shown) for operating hydraulic actuators 63 connectedto press assembly 71. Accordingly, press assembly 71 moves in a downwardstroke towards dispensed core 125. Press assembly 71 comes in contactwith dispensed core 125. As a downward motion of compression plate 81pushes on dispensed core 125, arms 107 rotate downwardly so that core125 is guided and centered on bottom plate 73 of the compressionsection. At the end of the downward stroke, arms 107 release thedispensed core 125 and the core is compressed against bottom plate 73 bycompression plate 81.

[0055] Press assembly 71 then returns to the full up position in anupward stroke, in which rotatable arms 107 rotate back to the holdingposition ready to accept a second core for flattening. Press positionsensor 85 detects the presence of press assembly 71 in the full upposition, in which controller unit 9 counts the number of downwardstrokes in the operational cycle. If desired, by counting the number ofdownward strokes more cores can be dispensed and flattened bycompression section 5 to form a single core board product. In theillustrated arrangement, two downward strokes are used in theoperational cycle.

[0056] Similarly as shown in FIG. 8, after detection of press assembly71 by sensor 85, a second core request signal is generated so thatsecond movable rod 37 opens to permit a second core to rest on rotatablearms 107 similarly as dispensed core 125. As shown in FIG. 10, thesecond core is then compressed against the flattened first dispensedcore 125. Microprocessor controller unit 9 determines that a seconddownward stroke has occurred so that in the extended position of thesecond downward stroke, the compressed cores are stapled together bystaple guns 77 against bottom plate 73. Following fastening of thecompressed cores, discharge gate 93 is opened vertically by pneumaticactuator 97 in which gate sensor 106 detects the predetermined openingto stop movement of the gate 93. Core board product 7 is then ejected byunload ram 61 by pushing bar 64 into a retaining bin 127.

[0057] After the method, as illustrated in FIGS. 11, 12A and 12B, a coreboard product 7 comprises at least two substantially flattened tubularpaper cores 12 fastened together in an abutting relationship by aplurality of integral fastening members 130. Fastening members 130 arepreferably located at discrete predetermined locations on the flattenedcores 12. Fastening members 130 can have any number of orientations anddirections on the tubular cores.

[0058] As shown in FIGS. 12A and 12B, in alternative embodiments,integral fastening members 130 have a first fastening portion 131abutting one of the flattened cores, two substantially perpendicularfastening portions 133 extending through each of the flattened cores.Winged portions 135 abut the flattened tubular core opposite of thetubular core abutted by first fastening portion 131. As shown in FIG.13, in an embodiment, grooves 129 located on bottom plate 73 aregenerally aligned with staple guns 77 to bend over the fastening memberto form the winged portions 135. The grooves have a configuration likeconventional stapler backing plates to bend over the ends of staples. Astrong board product is formed by resisting a springing effect of thesubstantially flatten cores. The springing effect occurs when acompressed core tends to open. As shown in FIGS. 12A and 12B, whenseveral compressed cores are layered together, first fastening portion131 and wing portion 135 of fastening member 130 resists the springingeffect of the compressed cores to form a relatively strong compressivebond between the flatten cores. Advantageously, core board product 7 isformed with an improved fastening arrangement that prevents tears inlarge paper rolls during rail transport operations by not separatingapart.

[0059] Referring to FIGS. 14-15, if desired, the tubular cores may becut into smaller sections by a semi-automated core cutting apparatus200. Control devices described in connection with core cutting apparatus200 can be operatively coupled to microprocessor controller 9 or aseparate controller unit. Referring to FIG. 14, in an embodiment, thecore cutting apparatus may comprises an elongated tubular core guide 201attached to a pivotal circular saw 203 for cutting a core into a smallercore section. Core guide 201 is constructed from a horizontally alignedforward tube 205, and a rear tube 207 with both having an insidediameter sized to accommodate one core. Tubes 205, 207 are horizontallysupported by support members 209 mounted on top of vertically disposedbeam members 211. Tubes 205, 207 can be constructed from steel pipes.Tubes 205, 207 are fastened to support member 209 and beam members 211by welding or other methods. The wall of forward tube 205 includes aslot opening 213 along its length so that an operator can slide anelongated core inside of the tube. Rear tube 207 has a predeterminedlength so that elongated cores are cut into a corresponding length.

[0060] Referring to FIG. 14, a gap 215 is formed between forward tube205 and rear tube 207 so that saw 203 is enabled to cut and separate ofthe core. A saw blade cover 217 is welded to both tubes 205, 207 onopposite sides of gap 215. Referring to FIG. 15, saw 203 is pivotallymounted to a support 219 by a pivot pin 221. Saw 203 is also mounted apneumatic actuator that is mounted so that upward and downward movementof a rod 223 of the actuator pivots saw 203 about pin 221. A sawproximity sensor 225 detects when saw 203 has pivoted into a downwardposition. Saw proximity sensor 225 is mounted in a vertical position todetect when a magnetic field is formed in a short distance at itssensing end. If desired, sensor 225 may be a mechanical switch, oroptical sensor to detect position of the saw.

[0061] Referring to FIG. 14, the top portion of discharge end 226 ofrear tube 207 preferably includes an opening for an optical sensor 227to detect the presence of the leading end of the core in tube 207. Nearoptical sensor 227 at discharge end 226, an air cylinder 229 is mountedin which its rod extends downward to block the movement of the core upondetection of the core leading end by sensor 227. Referring to FIG. 15,in use, upon detection of core leading end, the rod 223 moves downwardto the blade of saw 203 activates. During downward rotation of saw 203,the saw blade separates the core. Saw proximity sensor 225 detects theend of the rotation and saw 203 is pivot back by rod 223. While notshown, another proximity sensor detects when the saw in the up position.

[0062] A core clamping arrangement is provided at front end of tube 205prior to gap 215. The clamping arrangement includes an air cylinder (notshown) attached to a curved clamp (not shown) and return springs (notshown). In use, upon detection of the core leading end by sensor 227,the rod on air cylinder extends downward and forces the curved clamp onthe core against the inner surface of tube 205. As a result, the core isprevented from rotating while being cut by saw 203. The return springsmoved the clamp back up with the rod of the air cylinder after the coreis cut by the saw.

[0063] Thus, a core board forming apparatus 1 has been described forproducing core board product. Apparatus 1 is capable of producing a coreboard product about every 15 seconds while in operation. Thesubstantially precision operation of apparatus 1 reduces errors andenables a consistent board product without significant variations inproduct quality.

[0064] While the present invention has been described with reference toexemplary embodiments, it will be understood by those of ordinary skillin the art that various changes may be made and equivalents may besubstituted for elements thereof without departing from the scope of theinvention. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the inventionwithout departing from the scope thereof. Therefore, it is intended thatthe invention not be limited to the particular embodiment disclosed, butthat the invention will include all embodiments falling within the scopeof the appended claims.

What is claimed is:
 1. A core board product comprising at least twosubstantially flattened tubular paper cores being adjacent and fastenedtogether by a plurality of regular spaced fastening members extendingthough each of the said tubular cores, said fastening members beingconfigured to provide a resistive force for compressive bonding betweensaid tubular paper cores.
 2. The core board product in accordance withclaim 1, in which the fastening members each have a first fasteningportion with opposing ends, each of said opposing ends have integralsecond fastening portions extending substantially perpendicular fromsaid first fastening portion.
 3. The core board product in accordancewith claim 2, in which the first fastening portion is configured to abutagainst a first exposed surface of the at least two flattened cores andsaid second fastening portions extend through the at least two flattenedcores substantially perpendicular to the first fastening portion.
 4. Thecore board product in accordance with claim 3, in which each of thesecond fastening portions include a wing portion extending substantiallynormal therefrom and abutting a second exposed surface of the least twoflattened tubular paper cores, the second exposed surface being in anopposed position with respect to the first exposed surface.
 5. The coreboard product in accordance with claim 4, in which the wing portions aredirected inward towards each of the second fastening portions.
 6. Thecore board product in accordance with claim 4, in which the wingportions are direct outward away from each of the second fasteningportions.
 7. A core board product comprising at least two substantiallyflattened tubular paper cores fastened together by a plurality offastening members, the fastening members each having a first fasteningportion contacting against only one of the at least two flattened coresand two second fastening portions extending through the at least twoflattened cores substantially perpendicular to the first fasteningportion.
 8. The core board product of claim 7, wherein the fasteningmembers further comprise a third fastening portion abutting theflattened tubular core opposite of the flattened tubular core abutted bythe first fastening portion.